Recycled composite materials and related methods

ABSTRACT

Methods of producing particles of fiber and resin from fiber-resin composite materials are disclosed. The particles may be combined with a resin system and optionally combined with fillers, binders or reinforcements to produce new cured solid composite products.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a Continuation-in-Part of U.S. patentapplication Ser. No. 14/691,506, filed Apr. 20, 2015 entitled RecycledComposite Materials and Related Methods, which in turn is a Continuationof U.S. patent application Ser. No. 13/048,865 now U.S. Pat. No.9,028,731 also entitled Recycled Composite Materials and Related Methodsfiled on Mar. 15, 2011, and which claims priority benefit under 35U.S.C. § 119 of U.S. Provisional Application No. 61/340,286, filed onMar. 15, 2010. The present application also claims under 35 U.S.C. §119, the priority benefit of U.S. Provisional Application No.62/408,971, filed Oct. 17, 2016. All of the aforementioned patentapplications and patents are incorporated herein by reference in theirentirety.

FIELD OF THE INVENTION

The present embodiments herein relate to the recycling and reuse ofcomposite materials, in particular, to the recycling and reuse of windturbine materials to create composite materials, such as, particleboards.

BACKGROUND OF THE INVENTION Discussion of the Related Art

Nearly every industry utilizes fiberglass and fiber-reinforced materialsfor a variety of components and products. Worldwide demand for thesematerials has exploded due to an increased demand for both consumer andindustrial products, most notably in electronics, aircraft,construction, renewable energy, automotive, and infrastructuredevelopment (e.g. public structures). In the United States, China, andIndia, nearly 80% of consumer purchases are discarded after a singleuse. These economies offer a tremendous opportunity to capitalize on thesurplus of useable waste materials. The global demand for clean energyand infrastructure up-gradation is also expected to boost the compositefiber glass industry's growth in the future.

In many ways, however, fiberglass and fiber-reinforced materials havebecome problematic both in consumer and commercial markets due tonegative environmental effects. Fiberglass insulation, among otherproducts, for example, is now viewed as a potential hazard to theenvironment and one's health if inhaled. In fact, the state ofCalifornia mandates “fiberglass producers to use at least thirty percentpost-consumer cutlet in fiberglass building insulation made or sold inCalifornia” (California Integrated Waste Management Board, 2009). At thesame time, there is a growing demand for recycling and recycled consumerproducts in the U.S. According to the Environmental Protection Agency,Americans are recycling now more than ever in U.S. history. In 1990,Americans recycled 16% of waste, a percentage that increased to 32% in2005. Municipal solid waste also decreased by two million tons to justunder 246 million tons nationwide.

Fiberglass and other fiber-reinforced materials have long been difficultto recycle into new and useful products. Some manufacturers offiberglass goods, for example, are trying to dramatically increase useof reclaimed fiberglass in the production processes. While thesecompanies have investigated methods to reclaim fiberglass for consumerproducts both domestically and abroad, manufacturers have only been ableto obtain sufficient reclaimed fiberglass to replace ten to twenty-fivepercent of virgin resins used in fiberglass products. Wind turbine (WT)blades in particular, are large scale items comprised of glass fiber(fiber polymer matrix) composites (GFC) with a wood core in certainregions of the blade and often with a 70/30 GFC/wood ratio by weight.The polymer matrix can be thermoset resins such as epoxy, polyester orvinyl ester resins. The resin is cured (does not soften upon heating)and is part of the recyclable wind turbine (rWTB) mixture. Inproportion, glass fiber reinforced polymer (GFRP) representsapproximately two-thirds of the total weight of the blade. In manycases, such large-scale items, i.e., composite windmill turbine blades,are simply buried in landfills or burned.

There are many reasons for the interest in maximizing the use ofreclaimed fiber-reinforced products, such as recycling theaforementioned wind turbine blades. While reclaimed fiberglass offers away to reduce manufacturing costs, environmental concerns are alsomotivating manufacturers to reuse or recycle fiber-reinforced products.Consumers are showing a preference for environmentally awaremanufacturers, and the federal and state governments are ofteninvestigating the mandating of a timetable to eliminate fiberglass fromthe waste stream or mandating the use of recycled composite materials infinished goods.

A primary reason why past attempts at recycling fiberglass have failedis because a collection system to ensure an ample supply of incomingmaterials was not in place. In addition, many of the ventures failedbecause they could not get enough raw materials to meet the demands.Furthermore, the concerns of contingent liability prevented somegenerators from sending materials to be recycled.

With respect to wind turbine blades, such components have a predictedlifetime of 20 to 25 years and currently there is no acceptable andaffordable solution for breaking down the discarded materials andthereafter recycling such materials for reconstruction into beneficialalternative products. There are three different methods for recycling:mechanical, thermal, and chemical. The mechanical technique inparticular, which is the simplest method and the only solution presentlybrought to a commercial level, utilizes shredders, wherein the producedmaterial results in pieces of composites, glass fibers and a matrixpowder. The technique in particular attempts to reduce the amount ofvirgin glass fiber, which lowers the cost of the final reconstructedproduct. However, shredded composites, as the only reinforcement part inmanufactured composites has continued to be difficult.

With respect to the lack of recyclable fiber reinforced raw materials, apossible solution, which could also aid a correlated collection system,is to look at tracking the abundance of discarded blade componentsresultant from the wind farm industry so as to have a data base ofavailable discarded wind turbine blade components. However, there is nocurrent beneficial tracking methodology and/or system in place for thereuse, remanufacturing, incineration or disposal of the wind turbineblade material for recycling into beneficial products, such as the newpolymer composites, as disclosed herein.

Background information for a methodology of providing products fromrecycled reinforced plastics, is described and claimed in U.S. Pat. No.8,361,358 entitled “Method of Recycling Fiberglass reinforced Plastics,”filed Mar. 6, 2007, to Robert J Wolf, including the following, “[a]method of recycling fiberglass reinforced plastics. The steps includegrinding used fiber reinforced plastic material such as scraps with agrinder into a predetermined length to form a grinded reinforced plasticmaterial. The grinded reinforced material is then mixed with a mixingagent to form a composite material that is heated in order to cure thecomposite material to form a panel.”

Background information for a methodology of recycling waste compositematerial is described and claimed in U.S. Pat. No. 5,569,424, entitled“Method of Recycling Fiberglass reinforced Plastics,” filed Mar. 9,1995, to William E Amour, including the following, “[a] method andapparatus for recycling waste composite materials. The method includesprechopping cured waste composite materials into manageably sizedstrips, conditioning the prechopped strips into resin particulate andloose fibers having a length of approximately one-half to one andone-half inches, mixing the resin particulate and loose fibers with anuncured resin, and placing the resultant mixture into a mold having aforming surface contoured to form a composite part. The strips of thecomposite material are conditioned by running them through a conditionerthat includes a high-speed rotating blade. The rotating blade includes aplurality of angled cutting tips that chop up the waste compositematerial into loose fibers and resin particulate. The resin particulateand loose fibers pass through holes in a cylindrical screen thatsurrounds the cutting blade and cutting tips.”

Background information for a methodology of providing recycled fiberreinforced resin containing product, is described and claimed in U.S.Pat. No. 5,681,194, entitled “Recycled fibre reinforced resin containingproduct,” filed Dec. 12, 1994, to Richard Baker, including thefollowing, “[a] recycled fiber reinforced resin containing productcomprising a quantity of fiber reinforced resin pieces mixed togetherwith a quantity of granular aggregate material, and a binder, in whichthe fiber reinforced resin pieces and the granular aggregate areintermixed with and embedded in the binder, the binder being selectedfrom materials having an initially plastic state, in which fiberreinforced resin pieces and granular aggregate may be intermixed, andthe binder materials being thereafter hardenable at room temperatureinto a hard mass without the application of heat, and a method ofmanufacturing such a recycled fiber reinforced resin containing product,and apparatus for the manufacture of such a recycled fiber reinforcedresin containing product.” Additional background on recycling windturbine blades is described in, “Recycling of Wind Turbine Blades,”(www.appropedia.com) by Pearce et al., and as described in “Recycling ofWind Turbine Blades,” Renewable Energy Focus, by Pearce et al., No.9(7), pp 70-73, 2009.

Background information for a methodology of providing compositestructural components, is described and claimed in U.S. Application No.2001/0051249, entitled “Composite Structural Components for OutdoorUse,” published Dec. 13, 2001, to Gagas et al., including the following,“[a] structure according to the invention comprises a series ofinterconnected structural members. The structural members, such-aspanels, are made of a composition comprising as its first essentialingredient a cured (cross-linked) resin having sufficient strength whenfilled as described below to support weights up to about 700 poundswithout significant buckling, but which has sufficient resilience toflex and rebound from impacts such as low speed collisions with smallboats or dropping of heavy human-carried objects without cracking orbreaking. The cured resin matrix contains a first filler consistingessentially of inorganic particles effective to improve the impactresistance and flame resistance of the structure, and an amount of asecond filler consisting essentially of fibers effective to enhance therigidity of the structure and reduce crack propagation therein. Anoptional third filler consisting essentially of plastic microspheres maybe added in an amount effective to reduce the weight of the panel by atleast 10% without significantly affecting the other essential propertiesof the cross-linked resin and first and second fillers, namely flexuralstrength, flame resistance, impact resistance, rigidity, resistance tocrack propagation, and resistance to outdoor environments, particularlymarine environments. Piers and docks made from panels of the compositeof the invention provide superior performance as compared toconventional materials used to build such structures.”

Accordingly, a need exists for an improved methodology to extract andreuse different materials from wind turbine blades to not only addressenvironmental concerns but also to provide beneficial products, such as,but not limited to, novel composite panels. In addition, a need existsfor a tracking of such blades because as more blade manufacturers andwind farm operators use such a tracking system, there will be a greatervolume of blades being recycled because the process of recycling issimpler. Moreover, providing the information to enable a steady streamof materials to recycle allows for making recycling facilities perfectlyadapted to the volume of materials. Pickups of materials from wind farmsare also automated using the teachings herein to save time and money.

Moreover, tracking the status of windmill blades for the exampleembodiments herein can be of vital importance to particular recyclingfacilities. Specifically, knowing details of, for example, bladecreation, maintenance, and disposal time, such information can beutilized in using such blades for products of particular buyers so as toincrease repeatability for those who want consistency (e.g., so as tomaintain consistent ratio of glass fiber to wood) and to alert thosepurchasers of particular lots of discarded blades that may have providedless than desirable recycled products. The embodiments herein aredirected to such a need.

BRIEF SUMMARY OF THE DISCLOSURE

The disclosure relates to products that contain composite material aswell as methods of processing the material and methods of making theproducts. In many cases, the composite material is fiberglass or otherfiber-reinforced material, including recycled fiberglass or recycledfiber-containing material. The composite material is broken down intoparticles that are used in forming new products. The new products may bedesigned to emit no volatile organic compounds (VOCs) and no hazardousair pollutants, even in cases where the composite material emits VOCs orhazardous air pollutants prior to use, as disclosed herein. The productsmay be designed for use in structural applications, with non-limitingexamples being roads, railroad ties, traffic barriers, telephone polesand telephone pole cross bars, dock planking, sea walls, pilings, bumperstops, and posts. In other applications, the products may be for use innon-structural or decorative consumer products.

It is also to be appreciated that recycling of wind turbine material, asdisclosed herein, refers to a reprocessing operation to extract andreuse desirable materials. Such materials to be reprocessed/recycledoften include, but are not strictly limited to, recycled wind turbineblades (rWTB) so as to be utilized in applications, such as, forexample, composite particle/fiberboard panels. As disclosed herein, theparticular mechanical and physical properties of such recycled windturbine blade (rWTB) material are thus utilized in a beneficial way soas to provide a novel reinforcement in, as one non-limiting application,composite particle/fiberboards.

Moreover, desirable mechanical (e.g., modulus of elasticity (MOE),modulus of rupture (MOR) internal bond strength (IB)) and physical(e.g., density; moisture content; water sorption (i.e., absorptionand/or adsorption), thickness swelling density) properties of theproducts herein, (e.g., composite particle/fiberboards), can be variedin a manner to provide a desirable overall improved product with respectto similar materials on the market. Specifically, by utilizing recycledwind turbine blade (rWTB) material and by the utilization of, forexample, desired resin % (MDI %), Moisture Content % (MC %) added to anexisting moisture content in the material (e.g., of about 1.25%), alongwith other factors such as, but not limited to, additives, appliedpressing pressure, and heating schedule, etc., an improvedparticle/fiberboard product having variable properties s provided. As aprime example, the MOE (psi) of constructed rWTB compositesparticle/fiberboard is almost twice that of natural-based particleboard.Moreover, thickness swelling and water absorption properties of the rWTBcomposites particle/fiberboard are improved upon in the manufacturingmaterials.

To further appreciate the improvements to conventional naturalfiber-based composites, the configured resultant properties of theparticle/fiberboard composites herein include, hut are not limited to,an improved flame retardancy (based on its thermal stability), lessthickness swelling, and improved durability. Such resultant particlefiberboard materials can be used for substantially any number ofdomestic or non-domestic (industrial) applications, such as, forexample, added insulation, subflooring, home constructions, mobile homedecking, furniture, cabinets, pool tables, shelving, toys, signs, andwall linings, etc.

In a first aspect, the disclosure includes a method of processingcomposite material into smaller pieces, optionally with resin releasedfrom the material. In some cases, the composite material is fiberglassor another fiber-reinforced material, and the method produces pieces offiber and resin and/or pieces that are a mixture of fiber and resin. Insome embodiments, the small particles are used in forming new compositeproducts as disclosed herein.

In a second aspect, the disclosure includes a method of producingproducts with the processed composite material produced by a methoddisclosed herein. In some cases, the processed material is recycled orreclaimed fiberglass or fiber-reinforced materials as disclosed herein.

In some embodiments, the methods of the disclosure may be viewed as therecycling of composite materials or raw materials that are waste ordamaged beyond usefulness. In many embodiments, the composite materialsare large finished products, such as boat hulls, aircraft parts andcomposite windmill blades as non-limiting examples. In such cases, thecomposite materials may be further processed, before or after use in amethod disclosed herein, to remove undesirable contaminants orcomponents.

In other embodiments, the methods of the disclosure are practiced inrelation to producing composite products with recycled components.Recycled components of the disclosure include composite material, suchas fiberglass or other fiber-reinforced material, that has beenprocessed by a method disclosed herein. In many cases, the producedproducts emit no or low amounts of VOCs or hazardous air pollutants.

In further embodiments, the methods of the disclosure are practiced inrelation to a recycling program that sets baseline waste generationamounts and provides goals and targets for reducing waste generation.The program tracks waste reduction and may report results on an annualor other basis. Waste reductions may be converted to carbon equivalentsfor which certification may be provided.

In an additional aspect, the disclosure includes products that containcomposite material processed by a disclosed method. In many cases, theprocessed composite material is recycled or reclaimed fiberglass orother fiber-reinforced materials. The products may be structural ornon-structural and may also have decorative aspects.

In other non-limiting embodiments, the products include additionalcomponents such as rubber, plastics, aggregate solid particulates,aggregate rock, silica, fly ash, cement, sand, and other kinds ofcrushed rock or gravel. In further embodiments, the products areproduced by curing of processed composite material together with a resinsystem.

As another non-limiting aspect, a recycling method as disclosed hereinof producing a composite product includes: tracking one or morecomposite wind turbine blades, wherein the tracking further comprisescollecting and organizing information with respect to the composite windturbine blades utilized by an energy producer; processing the trackedone or more composite wind turbine blades so as to form pieces having atleast one dimension that is ½ inches or less of a resultant compositewind turbine blade material; mixing the processed resultant compositewind turbine blade material with one or more materials selected from: aresin, a water content, and one or more additives; forming the mixtureof processed composite wind turbine blade material into a shape forproviding a resultant composite product; and applying a pressure and atemperature to cure the formed mixture.

Another aspect of the embodiments herein is directed to a recyclingmethod of producing a flame retardant composite product, comprising:tracking a composite wind turbine blade material throughout its chain ofcustody; processing the wind turbine blade material identified in thetracking step to provide a plurality of wind turbine blade (WTB)feedstock pieces that are at least one inch or less in one or moredimensions; receiving the processed wind turbine blade (WTB) feedstockpieces at a processing facility (PPF); refining the processed windturbine blade (WTB) feedstock to provide a plurality of composite piecesranging from about 1/16 inches up to about ½ inches in one or moredimensions; spraying the plurality of composite pieces with one or moreliquids to provide a flame retardant composite mixture, wherein the oneor more liquids further comprises: a Polymeric methyl-diisocyanate (MDI)resin ranging from 3% up to about 10% in content, a water content, andone or more additives; forming the flame retardant composite mixtureinto a shape for providing a resultant flame retardant compositeproduct; hot pressing the formed flame retardant composite mixture at atemperature and pressure to cure the shaped composite mixture; andcutting, the cured flame retardant composite mixture to one or moredimensions in height, length and width to provide the resultant flameretardant composite product.

A further aspect of the embodiments herein is directed to a trackingmethod for recycling wind turbine blade materials, including;manufacturing one or more wind turbine blades; authenticating at abackend of a system that further includes: a solutions interface, amanufacturer interface, an energy producer interface, and a database,wherein authenticating further comprises providing a unique username andpassword; initiating a new record in a form provided at the backend,wherein the new record includes initial collected information of the oneor more wind turbine blades to be tracked throughout its chain ofcustody; storing the initiated new record in the data base; and editingthe form and thereafter storing after editing by way of the backend,wherein the editing is provided by a user of at least one of: thesolutions interface, the manufacturer interface, and the energy producerinterface, and wherein the editing further comprises utilizing screensat the backend to provide information selected from at least one of:blade creation, maintenance, disposal time, and any other relevantinformation related to the tracked one or more wind turbine blades.

Accordingly, using rWTB material for manufacturing compositeparticleboards is demonstrated to be an improvement over existingtechnologies and a beneficial solution for wind turbine blades that havereached maximum lifespan. Also, according to the results, rWTB materialcan be introduced to provide improved characteristics and enhancedmaterial properties of composites to enable novel particle/fiberboardproducts, as disclosed herein.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a chart illustrating a method of processing compositematerials

FIG. 2 is a chart illustrating a method of recycling composite materialsto produce new solid composite products.

FIG. 3 is a chart illustrating a method of processing compositematerials in parallel with processing of recycling or carbon credits.

FIG. 4 shows TGA curves for recyclable wind turbine (rWTB) material,pure glass fiber and pure wood for comparison for up to 800 C undernitrogen at the heating rate of 20° C. min⁻.

FIG. 5A shows bar plots of modulus of rupture (MOR) versus resin (i.e.,MDI %), moisture content *MC (%)) and size (inch) results.

FIG. 5B shows bar plots of MOE versus MDI (%), MC (%) and size (inch)results.

FIG. 5C shows bar plots of internal strength (IB) versus MDI (%), MC (%)and size (inch) results.

FIG. 6A, shows bar plots of MOR versus size and density results.

FIG. 6B shows bar plots of MOE versus size and density results.

FIG. 6C shows IB bar plots versus size and density results.

FIG. 7 shows bar plots of the modulus of elasticity (MOE) of differentparticle sizes of configured recyclable wind turbine (rWTB) materialoldie present embodiments so as to show the improvements thereof ascompared to conventional natural fiber-based particleboards.

FIG. 8A shows a comparison of thickness swelling of recyclable windturbine (rWTB) particle fiberboards versus MDI % over 2 hours and 4hours of immersion.

FIG. 8B shows a comparison of thickness swelling of recyclable windturbine (rWTB) particle/fiberboards versus MC % over 2 hours and 4 hoursof immersion.

FIG. 8C shows a comparison of thickness swelling of recyclable windturbine (rWTB) particle; fiberboards versus particle size over 2 hoursand 4 hours of immersion.

FIG. 8D shows a comparison of thickness swelling of recyclable windturbine (rWTB) particle/fiberboards versus density over 2 hours and 4hours of immersion.

FIG. 9A shows a comparison plot of water absorption over a range ofresin % (i.e., MDI %) and a reference conventional natural fiber-basedcomposite versus MC % over 2 hours and 4 hours of immersion.

FIG. 9B shows a comparison plot of water absorption over a range ofmoisture content (i.e., MC %) and a reference conventional woodcomposite.

FIG. 9C shows a comparison plot of water absorption over a range ofparticle sizes.

FIG. 9D shows a comparison plot of water absorption over a range ofdensity configurations for the composites.

FIG. 10 shows a system/software flowchart for tracking wind turbineblades for recycling purposes, as disclosed herein.

FIG. 11 shows an example screen of the tracking system/software forinputting data.

FIG. 12 shows an example screen of the tracking system/software, whereinediting of initial input data can be implemented.

FIG. 13 shows an example of the information architectural flow for thetracking/software system, as disclosed herein.

DETAILED DESCRIPTION OF MODES OF PRACTICING THE DISCLOSURE GeneralDescription

Recycling of wind turbine material, as disclosed herein, often but notnecessarily refers to a reprocessing operation to extract and reusedesirable materials. Such materials to be reprocessed/recycled ofteninclude, hut are not strictly limited to, recycled wind turbine blades(rWTB) in applications, such as, for example, composite panels. Inparticular, the mechanical and physical properties of such recycled windturbine blade (rWTB) materials are thus utilized in a beneficial way soas to provide a novel reinforcement in, as one non-limiting application,composite particle/fiberboards.

It is to be appreciated that desirable mechanical (e.g., modulus ofelasticity (MOE), modulus of rupture (MOR) internal bond strength (IB))and physical (e.g., density; moisture content; water absorption andthickness swelling density) properties of the products herein, (e.g.,composite particle/fiberboards), can be varied in a manner to provide adesirable overall improved product with respect to similar materials onthe market. Specifically, by utilizing recycled wind turbine blade(rWTB) material and by the utilization of, for example, desired resin(MDI %), Moisture Content % (MC %) added to an existing moisture content(e.g., of about 1.25%) along with other factors such as, but not limitedto, additives, applied pressing pressure, and heating schedule, etc., animproved particle/fiberboard product having variable properties isprovided.

Configured properties include, but are not limited to, an improved flameretardancy (based on its thermal stability), less thickness swelling,and improved durability as demonstrated by the disclosed resultantbeneficial mechanical properties herein (i.e., modulus of rupture (MOR),modulus of elasticity (MOE), and internal bond strength (IB)), as knownand understood by those of ordinary skill in the art. Such resultantparticle/fiberboard materials can be used for any number of domestic ornon-domestic (industrial) applications, such as, for example, addedinsulation, subflooring, home constructions, mobile home decking,furniture, cabinets, pool tables, shelving, toys, signs, and walllinings, etc.

As disclosed herein, the superior mechanical and physical effects ofusing rWTB material on manufacturing the composites particleboards areprovided. For example, the MOE, MOR and IB show significant enhancing inmechanical properties of the products herein, e.g., composite products(particle/fiberboards) compared to current products (naturalfiber/wood-based particleboard). As an example to be shown herein, theMOE (psi) of constructed rWTB composites particle/fiberboard is almosttwice that of natural fiber-based particleboard. Moreover, thicknessswelling and water absorption properties of the rWTB compositesparticle/fiberboard are improved upon in the manufacturing materials.

Accordingly, the obtained results indicate that using rWTB material formanufacturing composite particleboards is one of the best solutions forthe wind turbine blades that have reached maximum lifespan. Also,according to the results, rWTB material can improve characteristics andmaterial properties of the resultant particle/fiberboard compositesherein.

Specific Description

In the description of the invention herein, it is understood that a wordappearing in the singular encompasses its plural counterpart, and a wordappearing in the plural encompasses its singular counterpart, unlessimplicitly or explicitly understood or stated otherwise. Furthermore, itis understood that for any given component or embodiment describedherein, any of the possible candidates or alternatives listed for thatcomponent may generally be used individually or in combination with oneanother, unless implicitly or explicitly understood or stated otherwise.Moreover, it is to be appreciated that the figures, as shown herein, arenot necessarily drawn to scale, wherein some of the elements may bedrawn merely for clarity of the invention. Also, reference numerals maybe repeated among the various figures to show corresponding or analogouselements. Additionally, it will be understood that any list of suchcandidates or alternatives is merely illustrative, not limiting, unlessimplicitly or explicitly understood or stated otherwise. In addition,unless otherwise indicated, numbers expressing quantities ofingredients, constituents, reaction conditions and so forth used in thespecification and claims are to be understood as being modified by theterm “about.”

Accordingly, unless indicated to the contrary, the numerical parametersset forth in the specification and attached claims are approximationsthat may vary depending upon the desired properties sought to beobtained by the subject matter presented herein. At the very least, andnot as an attempt to limit the application of the doctrine ofequivalents to the scope of the claims, each numerical parameter shouldat least be construed in light of the number of reported significantdigits and by applying ordinary rounding techniques. Notwithstandingthat the numerical ranges and parameters setting forth the broad scopeof the subject matter presented herein are approximations, the numericalvalues set forth in the specific examples are reported as precisely aspossible. Any numerical values, however, inherently contain certainerrors necessarily resulting from the standard deviation found in theirrespective testing measurements.

For purposes of discussion herein, density with respect to productsherein is describe in units of psi or lb/ft³. The modulus of elasticity(MOE) also known as Young's modulus is a number that measures theresistance of the materials herein to elastic (recoverable) deformationunder load in units of psi. The modulus of rupture (MOR) (i.e., bendingstrength), is a measure of a product's strength before rupture in unitsof psi. Internal bond strength (IB) is the tensile strength in units ofpsi perpendicular to the surface, i.e., measure of the internal adhesiveperformance of the products. Thickness swelling (in inches), is animportant factor with respect to moisture effects and internal bondstrength, includes swelling of the final products itself.

As described herein, the disclosure includes a method of processing, orbreaking down, a composite material for subsequent use, such as theproduction of a product as disclosed herein. In some cases, the methodproduces particles from a composite material or a reclaimed (orrecycled) composite material. A disclosed method to break down compositematerial may include, as non-limiting examples, shredding or crushing,hammer milling, chopping, cutting, ripping, tearing, pounding, grinding,or otherwise degrading a composite material to form small pieces ofcomposite material. The small pieces of composite material may then beground to form smaller particles of composite material.

In some embodiments, a method of the disclosure is practiced with acommercial or industrial shredder and a commercial or industrialfiber-resin product grinder. In some cases, a shredder and/or grinder ofthe disclosure is portable such that the processing of compositematerial can occur on site or at the location of the material, therebyreducing transportation costs.

In many embodiments, the composite material used in a disclosed methodrecycles pre-existing composite products or raw materials that arewaste, surplus or damaged beyond usefulness. Non-limiting examples ofsources of such materials include cured or uncured scrap and ravingsfrom fiberglass and fiber-reinforced plastic manufacturers and productmanufacturers, boat hulls, and other marine equipment, composite turbineblades, including windmill blades, and aircraft parts. In many cases,the input materials are fiber-reinforced materials formed from polyesterand styrene resin. Non-limiting examples of fiber materials includefiberglass, graphite, carbon, nylon, and KEVLAR® and other syntheticfibers.

In some cases, the composite material is too large to fit into theshredder or grinder. Therefore, the methods of the disclosure mayinclude crushing, cutting, chopping, ripping, tearing or otherwisereducing large pieces of composite material to a size and shape thatfits into a commercial or industrial shredder, crusher, chopper orgrinder. Cutting or crushing processes or procedures are known in theart to reduce the size of the composite materials, including thoseprocesses and procedures that require air permits from the EnvironmentalProtection Agency (EPA) for indoor or outdoor operation.

In some embodiments, composite materials are sorted for size and contentprior to processing as disclosed herein. The composite materials mayalso be cleaned before processing with appropriate solvents or cleanersbefore, or during the breakdown process. In some cases, the cleaningoccurs before shredding. In many embodiments, the composite materialsinclude additional components that are undesirable for inclusion in newcomposite products, or foreign material has been combined with thecomposite materials. Non-limiting examples of such contaminants includewood products, and ferrous and non-ferrous metals. In such cases,additional processing of the composite materials may be performed toremove the contaminant(s). Non-limiting examples of additionalprocessing include exposure of composite materials to a magnet ormagnetic surface to attract and remove select metal contaminants. Suchmagnets may be part of a conveyance system such as a vibratory conveyor.By way of another example, pieces or particles of composite material maybe placed in a rotational device such as a centrifuge or cyclone andspun at high revolutions so that heavier objects such as pieces of metalor stone are separated from the lighter pieces or particles of compositematerial. Of course, multiple separation processes may be performed inrelation to each of the acts in a method of the disclosure. In manycases, any metal collected from these and other separation processesknown in the art may also be recycled.

The disclosure also includes methods such as the grinding of smallpieces of composite material into smaller particles of compositematerials. Optionally, the particles, which may comprise both fiber andresin, need not be separated into fiber and resin components asdisclosed in U.S. Pat. No. 5,569,424, which is hereby incorporated byreference as if fully set forth. The particles may be further used toform a solid composite product as disclosed herein. As a non-limitingexample, the particles may be combined with a resin system to produce asolid, fiber-reinforced composite product. In other cases, the particlesmay be combined with other dry binders, fillers, reinforcements, orstrengthening agents to produce a dry mixture product. In furtherinstances, the particles may be used as an additive or as astrengthening matrix to increase product life, strength, and/ordurability of an enhanced product. Non-limiting examples of an enhancedproduct include plastic resins, resin castings, casings, fiberboard,traffic barriers, railroad ties, planking, concrete, rubber and woodcomposite products.

In many embodiments, the small pieces to be ground down are no greaterthan about three inches in diameter. In other embodiments, the pieces ofthe invention are not greater than about 2.5 inches, not greater thanabout two inches, or not greater than about 1.5 inches in diameter. Insome embodiments, the pieces are less than about one inch to about threeinches in diameter. As used throughout this disclosure, the term “about”followed by a numerical value indicates a range that includes thenumerical value and values that are from ten (10) percent greater thanto ten (10) percent less than the numerical value.

In other embodiments, the small pieces may be in the shape or form ofrods, strips, cubes, rectangular prisms, cylinders, or irregular shapes,wherein the width or length of the shape is less than about 24 inches.In other embodiments, the pieces have a width or length less than about18 inches, less than about 12 inches, less than about 10 inches, lessthan about 8 inches, less than about 6 inches, less than about 4 inchesor less than about 2 inches.

In many embodiments, the disclosed grinding process produces particleswith an average fiber length of about one inch or less. In otherembodiments, the particles have an average fiber length of aboutone-half inch or less, about one-quarter inch or less, or aboutone-eighth inch or less. In some embodiments, the particles of theinvention have an average fiber length from about one-half inch to aboutone-eighth inch, or about one-half to about one-quarter inch, or aboutone-quarter to about one-eighth inch.

As described herein, a method of the disclosure comprises making orforming solid composite products with particles of composite material.The composite material may be “recycled” material produced by the breakdown process disclosed herein. The disclosure thus includes a method ofprocessing a composite material as described herein to form particles ofcomposite material that are then used to produce a solid compositeproduct. In some embodiments, the method includes shredding, crushingand/or grinding a composite material, such as a reclaimed material, intoparticles, combining the particles with resin to form a mixture,disposing the mixture into a form or a mold, and curing the mixture toform a solid composite product.

Of course particles produced in accordance with the disclosure may bestored separately or in mixture with one or more agent. Non-limitingexamples of agents include dry binders, fillers, catalysts,reinforcements, and strengthening agents suitable for use in forming acomposite product. As a non-limiting example, the ground compositematerial (particles) may be combined with aggregate rock and/or silicaand stored until use in production or manufacture of a compositeproduct.

In some embodiments, the resin may require a catalyst for operation. Inother cases, the resin does not require a catalyst. In some cases, theresin may require applied heat and/or pressure to cure, while in othercases the resin may be cured at room temperature. In yet other cases,the resins may also have been recycled from pre-existing materials.Non-limiting examples of resins include flowable plastic, polymer,epoxy, saturated and unsaturated non-styrenated polyester, and vinylester resins. In some cases, use of a styrene-free polyester resin willreduce or eliminate the outgassing of VOCs or hazardous air pollutantsfrom the cured solid composite product.

As disclosed, a method of the disclosure may include curing the mixtureof resin and particles, with or without the addition of other componentsand optionally without applied heat or pressure. In many cases, themixture is disposed, placed or poured into a form or mold. In othercases, the mixture is extruded into a form or closed molding. In furthercases, the mixture is poured into casts. In yet other cases, the mixturemay be formed into a large block or other shape from which multipleproducts may be machined or otherwise formed. In other embodiments,appropriate pressures and temperatures are applied to produce the curedproducts.

In some embodiments, a method of producing a composite product ispracticed with one or more additional components in forming a solidcomposite product. Non-limiting examples of components in aparticle-resin mixture include binders, fillers, resins, catalysts,reinforcements, and strengthening agents. Additional non-limitingexamples of components include aggregate solid particulates, aggregaterock, gravel, sand, wood, textiles, pipes, rods, bars, fibers, metals,honeycombs, spacers, tillers, resin, recycled resin, plastic resin,catalysts, recycled polymers, paper fibers, binders, cement, magnesiumoxide, water, cement, limestone, granite, chemical additives, andcombinations thereof. In some cases, an additional component is mixedinto the resin-particle mixture. In other cases, a component is disposedor placed into the form, mold, cast or the like prior to the addition ofthe mixture. In yet other cases, the component is disposed or placedinto the form, mold, cast or the like after the addition of the mixture.

The disclosure further includes a method of combining compositeparticles with binders, tillers or other reinforcement materials,optionally mixing the combination with resin, optionally disposing themixture in a mold and optionally curing the mixture.

As disclosed herein, a cured composite product comprises resin andparticles of composite, optionally fiber-reinforced, material. In manycases, the products may also include additional components such asaggregate rock, gravel, sand, wood, textiles, pipes, rods, bars, fibers,metals, honeycombs, spacers, fillers, resin, recycled resin, plasticresin, catalysts, recycled polymers, paper fibers, binders, cement,magnesium oxide, water, cement, limestone, granite, chemical additives,and combinations thereof.

As described, a composite product of the disclosure comprises resin andparticles of composite material. In some cases, the particles ofcomposite material form no more than about 50% by weight of the curedproduct. In other cases, the particles form no more than about 40%,about 30%, about 25%, about 20%, about 15%, about 10% or about 5% byweight of the cured product. Alternatively, in some cases the resincomprises less than about 50%, about 40%, about 30%, about 25%, about20%, about 15% or about 10% of the weight of the cured product.

In other embodiments, a composite product of the disclosure comprisesresin, particles of composite material and aggregate particulates oraggregate rock. In some cases, the particles of composite material formno more than about 50% by weight of the cured product. In other cases,the particles form no more than about 40%, about 30%, about 25%, about20%, about 15%, about 10% or about 5% by weight of the cured product. Insome cases the resin comprises less than about 50%, about 40%, about30%, about 25%, about 20%, about 15% or about 10% of the weight of thecured product. In other cases, the aggregate comprises less than about80%, about 70%, about 60%, about 50%, about 40%, about 30% or about 20%of the weight of the cured product. In yet other embodiments, theproduct further includes silica, which forms no more than about 40%,about 30%, about 25%; about 20%, about 15%, about 10% or about 5% byweight of the cured product.

In some embodiments, a composite product of the disclosure comprisesresin, particles of composite material, silica and aggregate rock. Insome cases, the ratio of these four components by weight in the curedproduct is about 25:15:20:40. In other cases, the ratio is about20:20:20:40 or about 25:10:20:45.

In other embodiments, a composite product of the disclosure maywithstand a compressive stress of at least about 10,000 psi with acompressive stress of less than about 7%. In further embodiments, theweight of a product of the disclosure may increase by less than about 1%after immersion in water for 24 hours.

Having now generally provided the disclosure, the same will be morereadily understood through reference to the following example which areprovided by way of illustration and are not intended to be limiting ofthe disclosure, unless specified.

EXAMPLES Example 1 Manufacture of Prototypes

Prototypes with dimensions of about 0.75″×1.0″×10″ were produced withthe following mixture:

-   -   23% resin by weight    -   15% ground recycled fiberglass product with ¼″ fiber length    -   20% silica    -   42% aggregate rock in varying sizes

The mixture was packed into a high density polyethylene molds and curedunder vacuum pressure. The prototypes were machined following curing.

Example 2 Prototype Testing—Flexural Bending

A flexural bending test was performed on prototypes according teaExample 1 with the following results.

TABLE 1 Displacement Max Width Thickness at Max Load Load MOE MORSpecimen (in) (in) (in) (in) (Psi) (psi) State 1 1.000 0.750 0.180 175.7213458 3012.4 Vacuum Bagged- Smooth 2 1.000 0.750 0.153 152.6 2093472786.7 Vacuum Bagged- Rough 3 1.000 0.750 0.140 210.4 337081 3605.0Vacuum Bagged- Smooth/Rough 4 1.000 0.750 0.135 158.7 217193 2719.8 HardPacked 5 1.000 0.750 0.154 177.6 195861 3044.4 Hard Packed 6 1.000 0.7500.118 130.5 115746 2236.8 Hard Packed Mean 1.000 0.750 0.148 169.2226448 2901.0 St. Dev 0.000 0.000 0.004 26.310 40245.683 450.980 COV0.000 0.000 16.267 15.546 17.773 15.546 The modulus of elasticity (MOE)and the modulus of rupture (MOR) calculations were performed for eachspecimen and an average was calculated. The sample had an average MOE of226,448 psi and a MOR of 2,901 psi.

Example 3 Prototype Testing—Compression

A compression test was performed on smaller sections of prototypesaccording to Example 1 with the following results.

TABLE 2 Compressive Compressive stress at strain at Modulus Extension atMaximum Maximum (automatic Width Thickness Max Load Max Load Load Loadyoungs) (in) (in) (in) (lbf) (ksi) (%) (psi) 1 0.996 0.990 −0.050−11573.953 11.74 6.18 339340 2 0.955 0.990 −0.045 −11138.159 11.73 5.96353341 3 0.904 0.990 −0.053 −10782.110 12.05 6.88 341853 4 0.944 0.984−0.043 −10934.716 11.77 5.62 367608 5 0.885 0.992 −0.044 −9776.653 11.155.55 358623 6 0.943 0.988 −0.054 −105683.755 11.47 7.07 314801 Mean0.938 0.989 −0.048 −10814.891 11.66 6.21 345928 St. Dev 0.039 0.0030.005 598.539 0.311 0.638 18520 COV 4.179 0.259 −10.061 −5.534 2.66710.275 5 The prototype sections performed remarkably well, averaging amaximum stress of 11,660 psi.

Example 4 Specimen Testing Water Absorption

Specimens were fully immersed in distilled water for a period of 24hours with the following results.

TABLE 3 Water Absorption Testing Initial Final Weight Weight WeightChange Specimen (g) (g) % 1 5.3553 5.3974 0.7851 2 3.6210 3.6503 0.62303 3.3694 3.3935 0.6637 4 4.3855 4.4224 0.8414 5 3.7204 3.7517 0.8413Mean 4.0903 4.1242 0.8311 St. Dev. 0.8006 0.8051 0.0290 COV (%) 19.574%19.547% 3.466% The specimens experienced an average weight change of0.8311%

Example 5

Referring to FIG. 1, composite materials are collected 1 from originalequipment manufacturers and other recycling sources. Composite materialsare cut to size in 10 with power saws or other cutting equipment to Fitinto an industrial or commercial shredder. The composite materials areshredded into pieces in 12, after which the pieces are placed in acommercial or industrial grinder in 14. The resulting compositeparticles are combined with resin system 16 and cured in 18 in a mold orform under applied pressure and temperature as necessary.

Example 6

Referring to FIG. 2, a windmill composite turbine blade weighing about22,000 pounds and about 220 feet long is collected and cleaned at 20.The blade is cut into sections each about 6.5″ by 85″ in height andwidth in 22 in order to fit into a commercial or industrial shredder.Each section is fed into a shredder of sufficient size that producessmall pieces of composite material of about 1.5″ to 2.5″ in diameter andnot more than 12″ in length in 24. The resulting pieces are fed into acomposite grinder at 26 using an appropriate screen size to produceground small particles of composite material with an average fiberlength of ¼ inch.

Additional tillers, binders or other reinforcement material, togetherwith a resin system, are introduced at 28. The fillers are aggregaterock and silica, and the resin is styrene-free polyester resin. Thecombined mixture is packed into a form or mold and cured to produce atraffic barrier in 30. The traffic barrier is treated with finishes thatare reflective and/or resist graffiti paints in 32.

Example 7

Ground small particles of composite material with an average fiberlength of ¼ inch is combined with aggregate rock, silica andstyrene-free polyester resin in a ratio of 42:20:15:23 and thoroughlymixed. The mixture is poured into a railroad tie mold in which a 4.5″diameter PVC pipe has been placed. The mixture is poured around andenrobes the pipe. The composite is cured at room temperature. Theresulting railroad tie withstands a minimum of 10,000 psi with less than7% compressive strain.

Example 8

Referring to FIG. 3, a system for processing composite materials forrecycling and tracking and applying recycling credits includes forexample in 40 collecting and organizing information relating tocomposite products, such as wind turbine blades, or other scrap parts,in a software program tailored to the needs of a wind energy producer.The damaged or scrap parts are processed according to the methods of thedisclosure in 42. The processor or recycler provides a certificate ofrecycling, or a certificate of deconstruction, to the wind energyproducer in 44. The processor or recycler, or their agents, may furthercollect and pass back to the energy producer the recycling credits in46. The processor or recycler combines the recycled composite materialswith resin and optionally other components to produce new solidcomposite products.

Example 9 Particle/Fiberboard Prototype and Materials and FabricationMethodology

Referring to FIG. 3, wind turbine composite material information iscollected and organized 40 (e.g., tracked) from manufactures and/or windenergy producers (wind energy farms) using the aforementioned softwareprogram discussed above in Example 8 and as to be discussed in moredetail below. The teachings for how a reduction to practice came aboutare discussed as follows.

Using the tracking system/software program disclosed herein, a windturbine blade was identified and was provided from a wind energyproducer. The blade was cut out from a load carrying beam configuredwith approximate dimensions of about 5 cm in width, about 5 cm in lengthand with an existing moisture content (MC) of about 1.25%.

The blade was thereafter collected 1 (see FIG. 1) and processed/shredded12 (i.e., cut, shredded (see reference characters 1, 10, 12 in FIG. 2;22, 24, 26 in FIG. 2; and/or 42 in FIG. 3)) using known machinery topalm size. The resultant composite material was thereafter shipped tothe Composites Materials and Engineering Center at Washington StateUniversity. While such material was configured to working dimensions bythe Wind Energy producer, it is to be appreciated that such reduction tosmaller sizes can also be configured at any site of choice.

The received material was then hammer milled through ½″, ¼″, ⅛″, 1/16″screen sizes. It is to be appreciated that the term ‘hammer milled’ forthis particular reduction to practice refers to smashing material intosmaller and smaller pieces until the pieces can pass through aparticular screen. While a hammer mill (e.g., a Bliss hammer mill) is abeneficial means, it is also to be appreciated that there are othermeans to achieve desired sizes, as known and understood by those ofordinary skill in the art. For example, a Hog mill, which haschisel-like striking elements to break the rWTB pieces against abreaking plate can also be used to provide the desired reduced-in-sizematerials.

Moreover, it is also to be appreciated that other means (e.g.,conventional mills which have been available in the open market) forproviding desired sizes can also be utilized and passed through aparticular screen to equally achieve desired sizes when appropriate, asunderstood by those of ordinary skill in the art.

To manufacture the new composites disclosed herein, (i.e.,particle/fiberboards), Polymeric methyl-diisocyanate (Rubinate 1840)(pMDI) was chosen as an exemplary resin but this does not exclude otherresins that can be utilized to provide the beneficial properties of theresultant panicle/fiberboards products disclosed herein. It is to benoted that MDI is beneficially formaldehyde free (thus resultantcomposites are formaldehyde free) and it polymerizes in the presence ofwater and thus in combination, reduces ecological risk concerns withrespect to the product(s) itself. However, it is also to be appreciatedthat the use of the disclosed % range of pMDI, because of its capabilityof forming desired chemical and mechanical bonds (i.e., highly reactiveand has strong bondability), is a preferred resin as it surprisingly andunexpectedly, contributes to the superior mechanical and physicalproperties of the resultant products disclosed herein.

In order to obtain comprehensive mechanical and physical properties ofdesirable rWTB composite particle/fiberboards, first, the effects ofusing different resin content, moister content and particle size on thematerial properties of manufactured composites were analyzed. Then,effects of density and using smaller particle size on thecharacteristics of rWTB composites particleboards were also evaluated sothat such information can be used to provide the novel methods andcomposite particle/fiberboards disclosed herein. For achieving thispurpose so as to enable the improved embodiments herein, eleven rWTBflame retardant composite particle/fiberboards were manufactured afteranalysis according to Table 4 as follows.

TABLE 4 Resin Particle Content MC Size Sample (%) (%) (inch) Density 1 65 ⅛ 65 2 6 5 ¼ 65 3 6 5 ½ 65 4 3 5 ½ 65 5 10 5 ½ 65 6 6 3 ½ 65 7 6 8 ½65 8 6 5 ⅛ 65 9 6 5 1/8 70 10 6 5 ⅛ 75 11 6 5 1/16 65

Table 4 above thus shows the detailed experimental plan. Forinvestigating the effects of resin content on the material properties ofrWTB composites particleboards, by considering a constant particle size,pMDI resin was sprayed into rWTB material with the levels of 3%, 6%, and10% (see under heading of “Resin Content” and as denoted by grey shadedregion), respectively. Three MC levels (3%, 5%, and 8%, see underheading of “MC %”) and as denoted by grey shaded region) were alsoadjusted by spraying water after spraying of pMDI resin.

At the second step, for considering the effect of density (mass per unitvolume or area (e.g., units of lb/ft³, psi) on the material propertiesof the manufactured particle/fiberboards, pMDI resin was sprayed intorWTB material with a constant level of 6%. After spraying pMDI resin,water was sprayed into rWTB material at the constant level of 5%, threedensity levels were considered (65, 70 and 75, see under heading of“Density” as also denoted by grey shaded region).

In order to manufacture composite particle/fiberboards with differentcontent, the resinated and moisturized rWTB was then hot pressed to asize of about a 14×14 inch particleboard with a thickness of 0.3 inches.The hot press temperature and time were set as 138° C. and 5 minutes,accordingly, which is often as disclosed herein for illustrativepurposes, but not always, a heating schedule for pMDI curing. Finally,after finishing the hot press process (see for example 42 in FIG. 3),eleven composite particle/fiberboards were cut from manufacturedcomposite panels.

For evaluating the material properties of rWTB composite particleboards,both the mechanical and physical properties of manufactured compositeparticleboard were investigated. Prior to testing, compositeparticleboards were kept in the conditioning room for 24 hours.Mechanical and physical tests were based on ASTM D1037-12 and comparedwith ANSI 208.1-2009. Statistical analysis was based on analysisvariance (ANOVA), Tukey comparison, as known to those skilled in theart.

Mechanical Properties: Flexural and IB

The IB test determined cohesion/adhesiveness of the panel in thedirection perpendicular to the plane of the panel. The test specimenswere 2 inches square and the thickness was 0.3 inches. The flexuralproperties were measured in three points bending test at roomtemperature. The tests were performed in accordance with ASTM D 1037-12.The bending test determined the flexural properties, (e.g., the modulusof elasticity MOE, modulus of rupture (MOR), as briefly discussed above.The span for the test was 24 times the nominal thickness of thespecimen. The load was applied at the center of the span to the topsurface. Moreover, the load was applied continuously during the test atthe uniform rate of motion of the crosshead of the testing machine.

Physical Properties: Water Absorption and Thickness Swelling

Water absorption tests were performed in accordance with ASTM D 1037-12.The conditioned specimens were immersed in water for 2 hours and 24hours at the temperature of 23±2 C. After 2 hours, the specimens wereremoved from the water and all surface water was wiped off with a cloth,and then were weighted. After 24 hours of immersion this processrepeated again. The percentage increase in weight (w) during immersionwas calculated as follows:

${w(\%)} = {\frac{m_{t} - m_{0}}{m_{0}} \times 100}$wherein m₀ and m_(t) are the conditioned and wet weights respectively.

Evaluating the thickness swelling is also similar to the waterabsorption. For evaluating the thickness swelling, the average thicknessswelling included the average of five points wherein four points at fourcorners of particleboard were considered with the fifth at the center.

Thermogravimetric Analysis (TGA)

FIG. 4 shows TGA curves recorded in nitrogen at a heating rate of 20° C.min⁻¹. In particular, TGA was carried out by heating the rWTB materialas well as pure glass fiber and pure wood for comparison, up to 800° C.under nitrogen at the heating rate of 20° C. min⁻¹. The thermaldegradation profiles of wood, glass fiber and rWTB material by TGArevealed that most of the degradation events occur between 300° C. and500° C. In particular, the glass fiber (see dashed curve 52) degradesover the 350° C. temperature, the rWTB (see curve 54 denoted by a solidline) material starts to degrade at the lower temperature level thanglass fiber, around 200° C., and wood (see curve 50) starts to degradeover a much lower temperature range, around 50° C. The degradationbefore 200° C. is almost for steam-explosion and water extraction. TheTGA results indicate that 48% of the total loss was contributed tothermoset resin, inserted wood material, and coating in the wind turbineblade 54 material, wherein 60% residue was assigned as the loss contentfor glass fiber 52. Because the wood 54 analysis revealed a largershoulder region, such a result indicated that the wood 50 material loses95% of its original weight. An important take-away from the curves shownin FIG. 4 is that the TGA results beneficially show that the rWTBmaterial 54 has very good thermal stability, as shown by the higherstarting decomposition temperature of about 250° C. in contrast to glassfiber 52 at about 200° C., and wood 50 at about 50° C.

Mechanical Properties of rWTB Composites

For evaluating the mechanical properties of rWTB composites, a threepoints bending test (flexure test to provide, for example, modulus ofelasticity) and an internal bond (IB) test (to determine adhesiveeffectiveness in correlation with other variables such as particle sizeand density of the composite were used.

Thus, FIGS. 5A-5C show mechanical properties of rWTB compositesparticleboards considering MDI (%), MC (%) and particle size effects inparticular. Specifically, FIG. 5A shows MOR versus MDI (%), MC (%) andsize (inch) results, FIG. 5B shows MOE versus MDI (%), MC (%) and size(inch) results, and FIG. 5C shows IB versus MDI (%), MC (%) and size(inch) results. Note that in FIG. 5C, the lowest IB is at least about100 psi. The lines denoted by the reference character 58 in FIGS. 5A-5Cindicate the requirements of the highest grade according to ANSi208.1-2009, which is the standard set forth for the requirements andtest methods for dimensional tolerances, as well as physical andmechanical properties for composite board. The indicated asterisks 59 inthe figures (only one denoted in FIG. 5A for simplicity) is used forsignificant differences based on ANOVA analysis, i.e., models used toanalyze the differences among group means and their associatedprocedures.

FIGS. 6A-6C show results of mechanical properties of rWTB compositesparticleboards considering density effects. Specifically, FIG. 6A, showsMOR versus size and density results, FIG. 6B shows MOE versus size anddensity results, and FIG. 6C IB versus size and density results.

FIG. 7 is finally shown comparing MOE of different particle size rWTBcomposites particle/fiberboards in contrast to a conventional wood basedparticleboard. Accordingly, FIG. 7 shows the MOE disparity ofconventional natural fiber-based composite boards as compared to theparticle/fiberboards MOE improvement of the present embodiments. Theplots also show that similar to the MOR results, the trend, as to bediscussed in more detail below, is that reducing the particle size alsoreduces the MOE.

According to the obtained surprising and unexpected results, resincontent (i.e., MDI %) provides superior properties compared toconventional materials with respect to MOE, MOR as well as IB. However,the results also indicate that MC % may not have a significant influenceon the mechanical properties for MOR, MOE, and IB. Importantly, rWTBcomposites particleboard with 10 MDI %, 5% MC and ½″ particle size hadthe maximum amount of MOE (i.e., 7.41E+5 psi) and the rWTB particleboardwith 1/16″ particle size, 6 MDI % and 5 MC % has the minimum amount ofMOE equal to about 3E+5 psi.

In addition, just like MOE, rWTB composites ½ inch particle/fiberboardwith 10 MDI % and 5 MC % had the maximum amount for both of the MOR andIB, i.e., 5.914E+5 psi and 34 psi respectively. The rWTB compositesparticleboard with 1/16 inch particle size has the minimum amount of MOR(2.290E+3 psi) and particle/fiberboard with 3 MDI %, 5 MC % and inchparticle size has the minimum amount of IB equal to 119 psi. Lastly, IBtests show that the best result is for ¼ inch particle size and similarto the MOE and MOR, 1/16 inch particle size has minimal effect for IBtest results as compared to the bigger particle sizes.

Also according to the obtained results, particle size also does not havea significant effect on the mechanical properties. Four particle sizesof ½″, ¼″, ⅛″ and 1/16″ were used. The results of MOE indicate thatthere is no considerable difference among ½″, ¼″, and ⅛″ in particlesize, by reducing the particle size to 1/16, MOE reduced more.

Thickness Swelling

Results of thickness swelling are given in FIG. 8A, FIG. 8B, FIG. 8C andFIG. 8D, comparing the results of thickness swelling for rWTBparticle/fiberboards of the present embodiments herein. In particular,FIG. 8A shows thickness swelling versus MDI %, FIG. 8B shows thicknessswelling versus MC percentage, FIG. 8C shows Thickness swelling versusparticle size, and FIG. 8D shows thickness swelling versus density. FIG.8A and FIG. 8B thus show MDI resin % and MC % being varied while under 2hours and 24 hours of immersion respectively for particle/fiberboardsdisclosed herein. The MDI %'s shown in FIG. 8A includes 3 MDI % 62, 6MDI % 64, 10 MDI % 66 compared against a natural fiber-basedparticleboard reference 68 (configured with 4% MDI, 10% MC wheat straw)while under 2 hours and 24 hours of immersion.

The MC %'s shown in FIG. 8B includes 3 MC % 69, 6 MC % 70, and 10 MC %71 compared against a natural fiber-based particleboard reference 68(configured with 4% MDI, 10% MC wheat straw) while under 2 hours and 24hours of immersion. With respect to FIG. 8C and FIG. 8D, the variablesfor those plots include particle sizes (FIG. 8C) ½″ 72, ¼″ 74, ⅛″ 76,1/16″ 78, and the variables for density (see FIG. 8D) include 65 lb/ft³82, 70 lb/ft³ 84, and 75 lb/ft³ 86, also while under 2 hours and 24hours of immersion.

Accordingly, thickness swelling for rWTB particle/fiberboards ascompared with natural fiber-based particleboard (i.e., reference 68)shows distinct improved characteristics of rWTB particle/fiberboards.The maximum amount of thickness swelling of rWTB particle/fiberboards(particle size=½″ 72, MD=3% 62, MC=5(%)) after 2 hours of immersion is1.96(%) and thickness swelling for the control sample after 2 hours is14.6(%).

Such a result indicates that the maximum thickness swelling ofparticle/fiberboards disclosed herein is 13% of natural fiber-basedparticleboard. Also, after 24 hours of immersion, the maximum thicknessswelling of rWTB particle/fiberboards is equal to about 3.69% and thethickness swelling of natural fiber-based particleboard after 24 h ofimmersion is about 27.3 This result indicates that after 24 hours ofimmersion, the maximum thickness swelling of rWTB composite particlefiberboards disclosed herein is 13.5% or less of a natural fiber-basedparticleboard 68.

The best result of thickness swelling after 2 hours of immersion is forparticle/fiberboards with particle size=⅛″ 76 and density=70 lb/ft³ 84(MDI=6% and MC=5%). In particular, the thickness swelling after 2 hoursof immersion is equal to about 0.11(%) and after 24 hours of immersionthe rWTB particleboard with 1/16″ 78 particle size and 65 lb/ft³ 82 hasthe minimum amount of swelling equal to 0.71%. In comparing the resultsof rWTB particle/fiberboards with the natural fiber-based particleboard68, thickness swelling of these two particular particle fiberboards is0.75% and 2.6% of natural fiber-based particleboard respectively.

With respect to MDI (%) (e.g., see FIG. 8A), after 24 hours ofimmersion, by increasing the amount of MDI (%) from 3% to 10% thicknessswelling reduced from 3.69% to 1.88%. Therefore, such a result indicatesthat MDI % has significant effect on the thickness swelling of rWTBcomposites particle fiberboards. Evaluating the effect of MC % (e.g.,see FIG. 8B), the results indicate that after 24 hours of immersion, byincreasing the amount of MC %, thickness swelling increased, and thereis no considerable difference between the thickness swelling of rWTBparticleboards with MC % of 3% and 5%. It is to be noted however that byincreasing the MC % to 8% (see reference character 71 in FIG. 8B), thethickness swelling increases to some degree.

Investigating the effect of density (lb/ft³) (e.g., see FIG. 8D),thickness swelling of rWTB composites particle/fiberboards disclosedherein shows that after 2 hours of immersion rWTB particleboards withparticle size=⅛″ and density=65 lb/ft³ absorb more water compared to therWTB particle/fiberboards with density equal to 70 lb/ft³ 84 and 75lb/ft³ 86, but after 24 hours of immersion by increasing the density,thickness swelling increased significantly.

Particle size (e.g., see FIG. 8C) investigation included keeping thedensity (lb/ft³) constant and equal to about 65 lb/ft³. Results showthat after 24 hours of immersion, thickness swelling reduced by reducingthe particle size. Thickness swelling is 1.93% for rWTB compositesparticle/fiberboard with ½″ 72 particle size. For the rWTBparticle/fiberboard with 1/16″ 78 particle size, thickness swelling isabout 0.71%.

Physical Properties Water Absorption

Water absorption results are presented in FIG. 9A, FIG. 9B, FIG. 9C andFIG. 9D. FIG. 9A shows water absorption versus MDI %. FIG. 9B showswater absorption versus MC percentage, FIG. 9C shows water absorptionversus particle size, and FIG. 9D shows water absorption versus density.For FIGS. 9A-9D, like reference characters found in FIGS. 8A-8D areutilized for simplicity of understanding.

Comparing the overall results of water absorption for rWTB compositedparticle/fiberboards with the reference particleboard (see referencecharacter 68 in FIG. 9A and FIG. 9B, MDI=4%, MC=10% wheat straw)indicate an excellent improvement over reference particleboard 68 byusing rWTB material.

After 2 hours of immersion, the natural fiber-based particleboardabsorbs 13.2% of water, wherein the maximum amount of absorbed water byrWTB composites particleboards is 2.74%. Such a result indicates thatthe maximum amount of absorbed water by reinforced particleboards isabout 20.75% of the water absorbed by natural fiber-basedparticleboards. Moreover, after 24 hours of immersion, the maximumamount of absorbed water by rWTB composites particleboards is 8.24% andit is just about 17.34% of the water absorbed by natural fiber-basedparticleboards, a vast improvement.

The minimum amount of absorbed water after 2 hours of immersion is about1.18% when the rWTB composites particle: fiberboards are configured withMDI=6%, MC>5% and ¼″ particle size. After 24 hours of immersion, thesame particle/fiberboard absorbed a minimum amount of water equal toabout 4.51%. Accordingly, after 2 hours the amount of absorbed water bythis particleboard was about 8.93% of the natural fiber-basedparticle/fiberboard and after 24 hours of immersion, the amount ofsorbed water (adsorbed or absorbed) was about 9.49% or less of thenatural fiber-based particleboard.

In specifically analyzing the data, the effects of MD on the waterabsorption of rWTB composites particle/fiberboards (e.g., see FIG. 9A),indicate that after 24 hours of immersion by increasing the MDI %, theamount of absorbed water reduced. By increasing the MDI % from 3% 62 to6% 64, the amount of absorbed water reduced desirably but by increasingthe MDI % from 6% 64 to 10% 6, the amount of absorbed water is notconsiderable.

Considering the effect of changing MC % on the water absorption of rWTBcomposites particle/fiberboard (e.g., see FIG. 9B), it is indicated thatby increasing the MC % from 3% 69 to 5% 70, or after increasing MC %from 5% 70 to 8% 71, rWTB composites particleboards appear to show lessabsorbed water.

Investigating the effect of density on the water absorption of rWTBcomposites particle/fiberboards (e.g., see FIG. 9D, with MDI % and MC %held constant), it is indicated that rWTB particle/fiberboards absorbedless water when the density increased from 65 (see reference character82) to 70 lb/ft³ (see reference character 82). However, after increasingthe density to 75 lb/ft³ (see reference character 82), there is nochange in the amount of absorbed water by rWTB particle/fiberboard.

For evaluating the effect of particle size on the water absorption ofrWTB composite particle/fiberboards (e.g., see FIG. 9C, density constantat about 65 lb/ft³, obtained results indicate that by reducing particlesize from ¼″ 74 to 1/16″ 78, rWTB particle/fiberboard absorbed morewater. However, the result is different for ½″ 72 particle size. Inparticular, rWTB composites particleboards with ½″ 72 particle sizeabsorbed more water than the particleboards with ¼″ 74. Specifically,the amount of absorbed water by rWTB particleboard with ½″ 72 isinterestingly close to the particleboard with ⅛″ 76.

Flame Spread Rate (FSR)/Flame Retardant Results

The flame retardant particle/fiberboard products were made using themethods as discussed above. Table 5 shown below illustrates thefire-retardant capabilities of the particle/fiberboards disclosed hereinas per the flame spread rate (FSR) testing (ASTM E-84) standards forsurface burning characterization of building materials, provided byGuardian Labs in Buffalo, N.Y.

Flame spread rate (FSR) is an industry metric of a material's propensityto burn rapidly and spread flames away from the source of ignitionacross the surface of a material or assembly. The purpose of suchtesting is to provide builders/architects/fire engineers, etc., withadequate information so that they can select appropriate material thatwill not contribute to the problem of life safety from fire withinstructures.

The methodology used for testing the materials disclosed herein entailedexposing the samples to a flame source to ignite them. The samples wereself-supporting and a ¼″ thick cement board was placed over the samplesas lid protection. The rate and the distance or the flames spread. i.e.,the FSR, were measured and assigned an index value based upon theresults. The ASTM E-84 industry rating is as follows: A=0-25, B=26-75,C=76-200, D=201-500, and E=over 500. Accordingly, the lower the rating,the longer it takes the composite to catch on lire and the slower aflame spreads.

Accordingly, as illustrated in Table 5 below, three 12″×12″ samples weretested for flame spread rates (FSR) to illustrate the beneficial flameretardant properties of the particle/fiberboards disclosed herein; 1)Washington State University (WSU) fiber/particleboard, and forcomparison testing: 2) natural fiber particle board and 3) Orientedstrand board (OSB) board.

While the details of the results testing are shown in Table 5 below, itis of note that the WSU particle/fiberboard (Sample 1) had an ASTMrating of A with no audible crackling or cracking/crack widening orflaming burning through the material in contrast to the Natural fiberparticle board (Sample 2) (also an A rating) though smoke levels weresimilar to that of the natural fiber particle board, which also had anASTM rating of A. The OSB board (Sample 3) had a “B” rating and burnedfor 1 minute and 24 seconds after torch removed in contrast to the WSUparticle/fiberboard (Sample 1) and the Natural fiber particle board(Sample 2).

TABLE 5 Time: WSU particle/ Natural fiber (Min- fiberboard ParticleBoard OSB Board Second) Test 1-Sample 1 Test 2-Sample 2 Test 3-Sample 100:00 Flame source on Flame source on Flame source on 00:15Discoloration; Light flaming; Light flaming; gaseous flaming;discoloration discoloration; light light smoke smoke 00:30 Flaming, andFlaming and Flaming and discoloration discoloration discolorationincrease; no increase; light increases flame spread smoke 01:00 Gaseousflaming Flaming and Gaseous flaming continues; discoloration increases;sample discoloration and continue to starts to crack; smoke increaseincrease; light smoke increases smoke; no flame (medium) spread 01:30 Noflame spread Gaseous flaming No flame spread increases; sample crackingat flame source area; smoke increases; no flame spread 02:30 No flamespread Gaseous flaming Cracks increasing increases; smoke and widening;increases: no flaming increases; no flame spread flame spread 03:00 Nochange to Cracking at flame Flaming decreases; sample; no flame sourceincreases; no flame spread; spread; medium no flame spread; medium-heavysmoke medium smoke smoke 04:30 No change to No change to Whitediscoloration sample sample of sample at flame source area; flamescontinue to decrease; medium smoke 05:00 No change to flaming burns Nochange to sample sample; no flame through material spread; mediumsurface, 1″ smoke diameter at flame source area 07:00 Flaming FlamingFlaming decreases decreases decreases; cracks widening; medium smoke09:00 No change to No change to Flaming continues sample sampledecreasing 10:00 Torch off; all Torch off; all Torch off; audible flamesout flames out crackling 11:00 N/A N/A Small gaseous flame; audiblecrackling continues 11:24 N/A N/A All flames out

Tracker

It was discussed above that the present embodiments herein can include asystem for processing composite materials for recycling and tracking andapplying recycling credits to include for example in 40 (see FIG. 3),collecting and organizing information relating to composite products,such as wind turbine blades, in a software program.

Generally, the embodiments herein incorporate a tracking system/softwaremethodology of manufactured wind turbine blades and/or resultantprocessed wind blade material (i.e., a Blade Tracker). However, whiletracking of wind turbine blades and/or wind blade material or lots ofthe blades or material for recycling purposes so as to provideparticle/fiberboards is a preferred embodiment, it must be noted thatthe tracking system/software can also be utilized to track any cured oruncured scrap, fiberglass, fiber-reinforced products, plastic, materialsfrom boat hulls, and aircraft parts, etc. if desired for purposes ofrecycling into composites.

FIG. 10 generally illustrates a system/software, as referenced by thenumeral 100, for tracking wind turbine blades, as disclosed herein. Thesystem 100 includes a controller and data system (generally shown byreference numeral 150), for monitoring and providing the user interfacemethodology. Controller and data system 150 is integrated withinterfaces, i.e., a wind firm operator interface 108, a blademanufacturer interface a solutions interface 120, and a blade databaseinterface 116 so as to enable forms and summary generation in a backend103, as provided by an individual's work station (e.g., the wind farmer,blade manufacture, or an administrator).

Wind Farm Operator Interface

Initially, a user (e.g., an engineer, operator, technician,administrator (e.g., associated with a manufacturer, wind farm etc.))opens a custom predesigned fixed and/or editable form 103 using aninterface 108 provided by the system/software 100 using for example, alogic processor (computer) to be discussed below. For ease of use, theopening of one or more initial or subsequent form(s) can be providedwith a graphical user interface (GUI). A form provided in the backend103 (backend refers to enabled access by users indirectly through anexternal application, i.e., Blade Tracker software) thus enables a userto manipulate data or select options and thereafter, view screens,provided by for example, the GUI to see data or output data.

The form upon first being generated enables a new record (an instance)of a given turbine blade to be tracked from the moment stored in thesystem 100, and followed via a chain of custody. The initial input andfollowing data input provides (assigns) initial data (blade creation,compositions, disposal time, any other relevant information (e.g.,particular notes of blade material, extraneous data, etc.) needed forblade tracking throughout its lifetime.

The user can choose what form that they want to generate, and then enterany additional details needed to complete the form. Maintenance data,for example, is one such data entry that can be entered into this formduring the blade's lifetime. There will be an option to either save theform or print it. There is also an option to automatically file (inmemory) that form as well. As stated above, there is, if desired, asummary provided with data about the wind farm as a whole, in which theoperator can see what blades are to be replaced, blades beingtransported to the farm, and various cost estimations and otherinformation.

Blade Manufacturer Interface

With respect to the blade manufacturer interface 112, as one exampleembodiment, the manufacturer user of system 100 can choose to select awind farm operator and specific blade which they would like to view. Theblade manufacturer can thereafter view all relevant information at ablade or farm level on a given screen (e.g., using the GUI) so that theycan plan production accordingly.

To aid in tracking the particular blade material or a material lot, themanufacturer can tag (an identifying tag) the material or lot for easeof tracking the chain of custody. The tag can be in the form of anon-machine readable label or other non-machine readable device.Examples of tags includes, but are not limited to, an RFID tag, abarcode, a hologram tag, or other suitable authentication device(s) thatare coupled, included, or affiliated with a particular blade orreconfigured material resultant from a respective particular blade.Accordingly, the identification tag enables a user to track the materialefficiently by having data entry by the manufacturer or subsequentholders of the material to be provided. For ease of use, suchinformation can be easily uploaded for data entry to an existing ornewly provided form and stored in the blade database 116 using system100. Ease of uploading the information can be enabled using for example,a scanner, a barcode reader, operator input, or processes known andunderstood by those skilled in authenticating tracking systems.

Solutions Interface

With respect to the solutions interface 112, an administrator can viewthe data of all wind farms in a wind farm specific or overall view, toallow for the planning of recycling efforts. There is also a form tomanipulate the data for any wind farm so that an administrator (e.g.,Global Fiberglass Solutions) can provide support to wind farm operatorshaving issues with their software.

The interfaces 108 (wind farm interface) and 112 (blade manufacturerinterface) and solutions interface 120 for inputting data through any ofthe means discussed above, enables vital information to be provided bythe database 116 with respect to, for example, blade creation,dimensions, compositions, etc.) maintenance, and disposal time. Asstated above, such information, in providing particle/fiberboardproducts for particular buyers, increases desired product repeatabilitycharacteristics but also alerts those purchasers of particular lots ofdiscarded blades that may resulted in less than desirable recycledproducts.

FIG. 11 illustrates an example screen of an order to be placed toinclude, for example, its identification ID (e.g., tagged ID) 124,associated date 126, units 128, and status 130. Also of note areassociated controls (e.g., forward and back buttons 132) and a webbrowser input window (an http request 134) to system 100 acting as aserver. The example http request 134 input window can thus enable othercontent, or perform other functions such as messaging a particular blademanufacturer. The response can and often contains information regardinga particular screen and associated tracked material. FIG. 12 illustratesan example screen wherein editing of initial input data can beimplemented. Example editing functionality includes editing installdates 140 and a window for providing informational notes 142. FIG. 13shows an example of the information architectural flow fortracking/software system 100. In particular, blade manufacturers and/orwind farm users can provide information on the models 156 for particularblades (so as to detail dimensions, compositions, etc.) and stored indatabase 116, as shown in FIG. 10. Orders 170 can be placed using formgeneration on the backend 103 (see FIG. 10) and tracked material of thelots 158 and units can be identified and ordered 166. As understoodherein, lot(s) refers to a particular group, collection and/or largenumber or amount of wind turbine blade(s) or blade composite material.

Every user(s) of the tracking system 100 can thus authenticate into thesystem 100 using a unique username and password. If a wind farm operatoror OEM decides to purchase the system 100, they are given a licensenumber, which they can use to create as many user accounts as they want.Blade manufactures and wind farm owners are linked together. A blademanufacturer is able to create accounts that can access the data fortheir respective customers. The solutions interface 120, as shown inFIG. 10, will also have access to the same data as the blademanufacturer and all wind farm operators. Data flow and operations asshown in FIG. 13 follows the procedures generally shown in FIG. 10.

Wind farm operators and blade manufacturers can make changes to data,while an administrator provides customer support issues. OEMmanufacturers (i.e., original equipment manufacturers) can also beprovided access to the data, often in a read-only state. The respectiveinterfaces communicates with the backend 103 (see FIG. 10) so as to makethe necessary changes in the database 116 (see FIG. 10).

Turning back to FIG. 10, the system 100 can be localized but is moreoften and preferably a web based system that beneficially enables accessfrom almost any computer with internet access, regardless of platform.Since the system can estimate when blades expire, recycling operationscan be planned very efficiently from system data.

As an illustrative discussion for system 400, as shown in FIG. 10, sucha system 100 can be directly or remotely directed by controller and datasystem of various circuitry of a known type. Such a control and datasystem 150 can thus be in the form of a desktop computer, a laptopcomputer, a network server, a server computer, or can be implemented byany one of or a combination of general or special-purpose processors(digital signal processor (DSP)), firmware, software, and/or hardwarecircuitry to provide instrument control, data analysis, etc., for theexample configurations disclosed herein.

Individual software modules, components, and routines may also beutilized by system 100, as shown in FIG. 10 in the form of the disclosedsoftware program, procedure, or process written in a suitableprogramming language, e.g., C, C#, C++. In addition, the computerprograms, procedures, or processes may be compiled into intermediate,object, or machine code and presented for execution as instructions andcontrol functions, so as to be implemented by system 100.

Various implementations of the source, intermediate, and/or object codeand associated data may also be stored in one or more computer readablestorage media that include read-only memory, random-access memory,magnetic disk storage media, optical storage media, flash memorydevices, and/or other suitable media. As used herein, the term “computerreadable storage media” excludes propagated signals, per se and refersto media known and understood by those of ordinary skill in the art,which have encoded information provided in a form that can be read(i.e., scanned/sensed) by a machine/computer and interpreted by themachine's/computer's hardware and/or software.

In preferred embodiments, system 100 is connected to other devices overother types of networks, including isolated local area networks and/orcellular telephone networks. The connection can also be a wirelessconnection or a physical coupling. As non-limiting examples of awireless connection, such an arrangement can include commercial wirelessinterfaces, such as but not limited to, radio waves (WiFi), infrared(IrDA), or microwave technologies that also allow integration intoavailable portable personal devices, such as, but not limited to, cellphones, pagers, personal identification cards, laptops, etc. Thewireless communication can thus provide signals, including alertmessages for expiring blades, etc.

With respect to physical wired coupling, the coupling can be by way of adedicated coupling I/O means such as a USB port (not shown) to provide,for example, operational data (feedback) via the embedded software(e.g., firmware) or instructions received from or to system 100 using,as one arrangement, controller and data system 150.

In some embodiments, system 100 can also include an internet-basedconfiguration interface (web-based platform) that enables remoteadjustment of stored information. The interface can be accessible via aweb browser, for example, over a secured or insecure network connection.The internet-based configuration interface permits remote updating ofsystem 100 by a central computer system or another device.

Such a web-based platform enables portability and compatibility withexisting customer systems. For a wind farm operation (i.e., an energyproducer using wind turbine blades), the system can store bladeinformation, generate all forms required for the blade, and makepredictions from the blade information. A blade manufacturer will havethe ability to view blade information and status from, for example, awind farm, and then make production predictions from that data. Anoversight organization with access can view all the data to planrecycling efforts and to act as an administrator.

In an exemplary method of operation using the tracker system 100 (seeFIG. 10), to illustrate how a composite panel can be finally provided, arWTB feedstock is received at a panel processing facility (PPF) in 1″minus (less than 1″ in any orientation) particles (tracker softwareutilized to track this material so as to maintain consistent ratio ofglass fiber to wood). Initial grinding of the blade is done in the field(e.g., at a wind farm where material is to be discarded) with mobileequipment to get it down to a 1″-minus size fraction (e.g., at least oneinch or less in one or more dimensions). The rWTB is further refinedwith a hammer-mill (or similar mechanical mill) to a consistent sizeideal for the panel produced. The refined rWTB is then sent to a dryblender system, either continuous or batch, sprayed with resin,potentially water, and any other processing additives that may beconsidered. Resin, water and liquid additives are generally sprayed withair pressure where the liquids are air atomized and then dispersed onthe surface of the rWTB. The rWTB that has been dry blended with theresin and other additives (called the “furnish”) is then formed into anevenly distributed mat on a continuous belt. The formed continuous matof furnish then enters a press, where pressure and heat are applied tothe mat. After 2-10 minutes, the resin has cured and the panel is pushedout of the press. The panel is cut to the desired dimensions and sandedto smooth the surface for secondary lamination or final use.

Having now fully described the inventive subject matter, it will beappreciated by those skilled in the art that the same can be performedwithin a wide range of equivalent parameters; concentrations, andconditions without departing from the spirit and scope of the disclosureand without undue experimentation.

It is to be understood that features described with regard to thevarious embodiments herein may be mixed and matched in any combinationwithout departing from the spirit and scope of the invention. Althoughdifferent selected embodiments have been illustrated and described indetail, it is to be appreciated that they are exemplary, and that avariety of substitutions and alterations are possible without departingfrom the spirit and scope of the present invention.

We claim:
 1. A recycling method of producing a flame retardant compositeproduct, comprising: tracking a composite wind turbine blade materialthroughout its chain of custody; processing the wind turbine bladematerial identified in the tracking step to provide a plurality of windturbine blade (WTB) feedstock pieces that are one inch or less in one ormore dimensions; receiving the processed wind turbine blade (WTB)feedstock pieces at a processing facility (PPF); refining the processedwind turbine blade (WTB) feedstock to provide a plurality of compositepieces ranging from about 1/16 inches up to about ½ inches in one ormore dimensions; spraying the plurality of composite pieces with one ormore liquids to provide a flame retardant composite mixture, wherein theone or more liquids further comprises: a polymeric methyl-diisocyanate(MDI) resin ranging from 3% up to about 10% in content, a water content,and one or more additives; forming the flame retardant composite mixtureinto a shape for providing a resultant flame retardant compositeproduct; hot pressing the formed flame retardant composite mixture at atemperature and pressure to cure the shaped composite mixture; andcutting the cured flame retardant composite mixture to one or moredimensions in height, length and width to provide the resultant flameretardant composite product.
 2. The recycling method of claim 1, whereinthe water content comprises about a 5% moisture content (MC) added to anexisting moisture content.
 3. The recycling method of claim 1, whereinthe one or more additives further comprises at least one of: binders,fillers, catalysts, strengthening agents, fillers, aggregate solidparticulates, aggregate rock, gravel, sand, wood, textiles, pipes, rods,bars, fibers, metals, honeycombs, spacers, fillers, catalysts, recycledpolymers, paper fibers, binders, cement, magnesium oxide, cement,limestone, granite, silica, and chemical additives.
 4. The recyclingmethod of claim 1, wherein the tracking step further comprisescollecting and organizing information with respect to the composite windturbine blade material utilized by an energy producer.
 5. The recyclingmethod of claim 4, wherein the tracking step further comprises checkingfor a consistent glass to wood ratio of the collected information of thecomposite wind turbine blade material.
 6. The recycling method of claim4, wherein the tracking step further comprises recycling credits back tothe energy producer.
 7. The recycling method of claim 1, furthercomprising: tagging the manufactured one or more wind turbine blades ora processed material resulting from the one or more manufactured one ormore wind turbine blades or tagging a collection of manufactured one ormore wind turbine blades or tagging processed materials resulting fromthe collection of manufactured one or more wind turbine blades, whereinthe tagging enables ease of tracking the chain of custody.
 8. Therecycling method of claim 7, wherein the tagging further comprises a tagin the form of at least one of: a non-machine readable label, anon-machine readable device, an RFID tag, a barcode, and a hologram tag.9. The recycling method of claim 1, wherein the resultant flameretardant composite product is a particle/fiberboard configured withmechanical properties that further comprises: a modules of elasticity(MOE) of up to about 7.41E+5 psi, a modulus of rupture (MOR) of up toabout 5.914E+5 psi, and an internal bond strength (IB) of at least 100psi.
 10. The method of recycling claim 1, wherein the resultant flameretardant composite product is a particle/fiberboard configured so thatthe amount of sorbed water is less than about 9.49% of a naturalfiber-based particleboard after 24 hours of immersion and wherein theresultant flame retardant composite product is configured so that amaximum thickness swelling is less than about 13.5% of a naturalfiber-based particleboard after 24 hours of immersion.